JP7581325B2 - Linear surgical stapler - Google Patents

Description

In some surgical procedures, such as gastrointestinal anastomosis, it may be desirable to clamp one or more layers of tissue, cut the clamped layers, and simultaneously drive staples through the layers to substantially seal the cut layers of tissue together near their cut ends. One such instrument that may be used in such procedures is a linear surgical stapler, also referred to as a "linear cutter." Linear surgical staplers generally include a first half (referred to as the "cartridge half" or "reload half") having a distal jaw configured to support a staple cartridge (or "reloader"), and a second half (referred to as the "anvil half") having a distal jaw supporting an anvil face having a staple forming mechanism. The stapler further includes a movable clamp lever configured to releasably clamp the stapler halves together. The stapler halves are configured to pivot relative to one another to receive and clamp tissue between the two distal jaws when the clamp lever is closed. The stapler firing assembly is configured to operate to simultaneously sever the clamped layers and drive staples through the tissue on either side of the cut line. After firing the stapler, the clamp lever may be released and the stapler halves may be separated to release the cut and stapled tissue.

While many different types of surgical stapling instruments and related components have been made and used, it is believed that no one prior to the present inventors has made or used the invention described in the accompanying claims.

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the general description of the invention given above and the detailed description of the embodiments given below, serve to explain the principles of the invention.
FIG. 1 is a perspective view of an exemplary linear surgical stapler showing the cartridge and anvil halves of the stapler coupled together with the clamp lever of the cartridge half in a fully closed position. FIG. 2 is an exploded perspective view of the linear surgical stapler of FIG. 1; 2 is a perspective view of a proximal portion of the cartridge half of the linear surgical stapler of FIG. 1 , showing a cross-section of the cartridge channel and a clamp lever in an open position to show the internal workings of the cartridge half; 2 is a top perspective view of the firing assembly of the linear surgical stapler of FIG. 1 ; 2 is a side elevational view of the linear surgical stapler of FIG. 1 showing the stapler halves separated from one another; 2 is a side elevational view of the linear surgical stapler of FIG. 1 showing the proximal ends of the stapler halves connected together; 2 is a side elevational view of the linear surgical stapler of FIG. 1 showing the distal pin of the anvil half received by the clamp lever jaws of the cartridge half; 2 is a side elevational view of the linear surgical stapler of FIG. 1 illustrating the closing of the clamp lever to fully clamp the stapler halves together; 2 is a side elevational view of the linear surgical stapler of FIG. 1 illustrating distal actuation of the firing assembly with the stapler halves fully clamped; 2 is a perspective view of an exemplary staple cartridge configured for use with the linear surgical stapler of FIG. 1 ; FIG. 7 is an exploded perspective view of the staple cartridge of FIG. 6; FIG. 7 is an enlarged perspective view of the staple cartridge of FIG. 6 showing tissue gripping mechanisms disposed along the length of the deck surface of the staple cartridge; 9 is an end cross-sectional view of the staple cartridge of FIG. 6 taken along section line 9-9 of FIG. 6; FIG. 7 is an enlarged top plan view of a tissue gripping mechanism disposed on the deck surface of the staple cartridge of FIG. 6 . FIG. 7 is an enlarged perspective view of a tissue gripping mechanism disposed at the distal end of the deck surface of the staple cartridge of FIG. 6 . FIG. 7 is a perspective view of an exemplary staple driver pair and respective staples of the staple cartridge of FIG. FIG. 13 is an enlarged perspective view of the top of the staple driver of FIG. FIG. 13 is a top view of the staple driver of FIG. 7 is a side elevational view of a portion of the staple cartridge of FIG. 6 and a facing portion of the anvil face of the anvil half of the surgical stapler of FIG. 1 , showing the stapler portions cooperating to form a pair of staples; FIG. FIG. 16 is a plan view of the pair of staples of FIG. 15 in a formed state; FIG. 7 is a perspective view of another exemplary pair of staple drivers configured for use with the staple cartridge of FIG. FIG. 18 is an enlarged perspective view of the top of the staple driver of FIG. FIG. 18 is a top view of the staple driver of FIG. 18 is an enlarged perspective view of one of the staple drivers of FIG. 17 in combination with staples formed by the staple drivers cooperating with anvil pockets of the anvil half of the linear surgical stapler of FIG. 1 ; 5 is a perspective view of an underside of a proximal portion of the firing assembly of FIG. 4 configured for use with the linear surgical stapler of FIG. 1 ; 2 is an enlarged cross-sectional perspective view of a portion of a cartridge half of the linear surgical stapler of FIG. 1 , showing an exemplary guide block through which a firing beam of the firing assembly is configured to translate; FIG. 23 is a perspective view of the guide block and lockout spring of the cartridge half of FIG. 22 . FIG. 24 is a perspective view of the lockout spring of FIG. 23 . FIG. 23 is a plan view of the guide block, lockout spring, and firing beam of the configuration of FIG. 22 . FIG. 23 is a plan view of another exemplary lockout spring in combination with the guide block and firing beam of the configuration of FIG. 2 is an enlarged side cross-sectional view of a cartridge half of the linear surgical stapler of FIG. 1 illustrating the knife beam of the firing assembly in a raised, locked out position relative to the guide block prior to insertion of an unused staple cartridge; An enlarged side cross-sectional view of the cartridge half of the linear surgical stapler of Figure 1 showing the knife beam in a lowered, firing position relative to the guide block after insertion of an unused staple cartridge, represented by a schematic diagram of the extended swing tab of the staple cartridge. 2 is an enlarged side cross-sectional view of a cartridge half of the linear surgical stapler of FIG. 1 showing distal actuation of the firing assembly on the lockout spring; 11 is an enlarged cross-sectional perspective view of a portion of a cartridge half of the linear surgical stapler of FIG. 1 , illustrating an exemplary alternative guide block through which the firing beam of the firing assembly is configured to translate; FIG. 30 is a perspective view of the guide block and lockout spring of the cartridge half of FIG. 28 . 29 is an enlarged side cross-sectional view of the cartridge half of FIG. 28 showing the knife beam of the firing assembly in a raised, locked out position relative to the guide block prior to insertion of an unused staple cartridge; An enlarged side cross-sectional view of the cartridge half of Figure 28 showing the knife beam in a lowered, firing position relative to the guide block after insertion of an unused staple cartridge, represented in schematic form by the extended swing tab of the staple cartridge. FIG. 30 is an enlarged side cross-sectional view of the cartridge half of FIG. 28 showing distal actuation on the lockout spring of the firing assembly; FIG. 13 is a side view of a distal portion of another exemplary anvil half of a linear surgical stapler, showing a distal jaw portion having a concavely curved mounting surface and an anvil plate having a similar concave curvature. 32A is a cross-sectional end view of the distal jaw portion of the anvil half of FIG. 31 taken along section line 32A-32A of FIG. 31 with the distal tip structure omitted. 32B is a cross-sectional end view of the distal jaw portion of the anvil half of FIG. 31 taken along section line 32B-32B of FIG. 31. 32C is a cross-sectional end view of the distal jaw portion of the anvil half of FIG. 31 taken along section line 32C-32C of FIG. 31. FIG. 32 is a side elevational view of a distal portion of a linear surgical stapler having the anvil half of FIG. 31 and the cartridge half of FIG. 1 , showing the stapler half in a partially clamped state with the shroud of the stapler half omitted and the anvil plate in a concave curved configuration; 33B illustrates a side elevational view of the distal portion of the linear surgical stapler of FIG. 33A showing the stapler halves in a fully clamped state with the anvil plate in a straight configuration. 11 is a schematic side elevation view of another exemplary staple cartridge and distal portion of an anvil half of a linear surgical stapler showing a staple cartridge having staple drivers of different heights;

The drawings are not intended to be limiting in any manner, and it is contemplated that various embodiments of the invention may be embodied in other various ways, including those not necessarily depicted in the drawings. The accompanying drawings, which are incorporated in and form a part of this specification, illustrate several aspects of the invention and, together with the description, serve to explain the principles of the invention. It will be understood, however, that the invention is not limited to the precise arrangements shown.

The following description of specific examples of the present invention should not be used for the purpose of limiting the scope of the present invention. Other examples, features, aspects, embodiments, and advantages of the present invention will become apparent to those skilled in the art from the following description, which illustrates, by way of example, one of the best modes contemplated for carrying out the present invention. As will be understood, the present invention is capable of other different and obvious aspects, all without departing from the present invention. Thus, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.

For clarity of this disclosure, the terms "proximal" and "distal" are defined herein relative to a surgeon or other operator gripping a surgical instrument having a distal surgical end effector. The term "proximal" refers to the location of an element disposed closer to the surgeon, and the term "distal" refers to the location of an element disposed closer to the surgical end effector of the surgical instrument and farther from the surgeon. Also, to the extent that spatial terms such as "upper," "lower," "vertical," "horizontal," and the like are used herein with reference to the drawings, it will be understood that such terms are used for illustrative descriptive purposes only and are not intended to be limiting or absolute. In that regard, it will be understood that surgical instruments such as those disclosed herein may be used in a variety of orientations and positions, not limited to those shown and described herein.

As used herein, the term "about" or "approximately" of any numerical value or range is intended to indicate a suitable tolerance of dimensions that allows a portion or collection of components to function for its intended purpose as described herein.

I. Exemplary Linear Surgical Stapler A. Overview of the Linear Surgical Stapler Figures 1 and 2 show an exemplary linear surgical stapler (10) (also referred to as a "linear cutter") suitable for use in various cutting and stapling procedures, such as gastrointestinal anastomosis procedures. The linear surgical stapler (10) includes a cartridge half (12) (also referred to as a "reloading half") and an anvil half (14) configured to releasably couple together to clamp tissue therebetween for simultaneous cutting and stapling of the clamped tissue.

The cartridge half (12) includes an elongated cartridge channel (16) having a proximal frame portion (18) and a distal jaw portion (20). The proximal frame portion (18) slidably retains the firing assembly (100) and includes a pair of laterally opposed upright side flanges (22). Each side flange (22) includes a vertical slot (24) disposed at its distal end and a tapered notch (26) disposed at its proximal end. An outwardly projecting reinforcing rib (28) extends longitudinally between the distal slot (24) and the proximal notch (26) of each side flange (22) and is configured to provide the side flanges (22) with increased stiffness. An outwardly flared upper segment (30) defines an upper edge of the proximal portion of each side flange (22) and is configured to facilitate receipt of the anvil half (14) by the cartridge half (12). Each side flange (22) further includes an elongated firing slot (32) extending longitudinally along an underside of the side flange (22) between the proximal notch (26) and the distal slot (24). The elongated firing slot (32) is configured to guide the firing assembly (100) between the proximal and distal positions. The firing assembly (100) is described in more detail below in conjunction with FIG. 4. The distal jaw portion (20) of the cartridge channel (16) is configured to receive (or "reload") a staple cartridge (130), which is described in more detail below in conjunction with FIGS. 6-20.

The cartridge half (12) further includes a clamp lever (40) (also referred to as a "latch lever") pivotally coupled to the cartridge channel (16) with a clamp lever pivot pin (42) disposed approximately in alignment with the distal slot (24) of the cartridge channel side flange (22). The clamp lever (40) includes an elongated lever arm (44) having a free proximal end (46) and a distal end pivotally coupled to a lower portion of the cartridge channel (16) with the pivot pin (42). A pair of opposed jaws (48) extend distally from the distal end of the lever arm (44) adjacent the cartridge channel side flange (22). Each jaw (48) includes a curved slot (50) having a closed proximal end and an open distal end configured to receive a latch pin (68) of the anvil half (14), as described below.

The clamp lever (40) is operable to pivot relative to the cartridge channel (16) between an open position in which the proximal end (46) of the lever arm (44) is spaced away from the cartridge channel frame portion (18) and a closed position in which the proximal end (46) faces the cartridge channel frame portion (18). As shown and described below in connection with Figures 5C-5D, actuation of the clamp lever (40) from the open position to the closed position functions to capture opposite lateral ends of the latch pin (68) within the jaw slots (50) of the clamp lever, thereby clamping the anvil half (14) to the cartridge half (12). In this regard, the curvature of each jaw slot (50) defines respective upper and lower camming surfaces configured to engage and pull respective lateral ends of the latch pin (68) toward the cartridge channel (16) when the clamp lever (40) is pivotally closed. A resilient member, shown in the form of a flat spring (52), biases the lever arm (44) toward the open position. The flat spring (52) thus facilitates disengagement of the clamp lever jaw (48) from the anvil half latch pin (68) upon initial advancement of the clamp lever (40) from the closed position toward the open position. As best seen in FIGS. 2 and 3, the clamp lever (40) further includes a latch member (54) disposed at the proximal end (46) of the lever arm (44). The clamp lever latch member (54) is configured to resiliently and releasably engage the proximal end of the frame portion (18) of the cartridge channel, thereby releasably retaining the clamp lever (40) in the closed position, for example, during firing of the stapler (10).

The anvil half (14) of the linear surgical stapler (10) includes an elongated anvil channel (60) having a proximal frame portion (62) and a distal jaw portion (64). The proximal frame portion (62) includes a pair of laterally opposed upright side flanges (66) configured to be received between the cartridge channel side flanges (22) when the anvil half (14) is coupled with the cartridge half (12). A distal latch projection in the form of a latch pin (68) extends laterally through the distal end of the anvil channel side flanges (66), and a proximal pivot projection in the form of a proximal pin (70) extends laterally through the proximal end of the anvil channel side flanges (66). The anvil pins (68, 70) are configured to facilitate coupling of the anvil half (14) with the cartridge half (12), as described below.

The distal jaw portion (64) of the anvil half (14) supports an anvil plate (72) that defines an anvil face having a plurality of staple-forming pockets (74) (see FIG. 15) configured to deform the legs (174) of the staples (170) ejected by the staple cartridge (130) when the stapler (10) is fired, e.g., as described in more detail below. In some variations, the anvil face can be formed integrally with the distal jaw portion (64). The distal jaw portion (64) of the anvil half (14) further supports a tapered distal tip member (76). In some variations, the distal tip member (76) can be selectively expandable relative to the distal jaw portion (64) in accordance with the teachings of U.S. Patent Application No. 16/165,587, filed October 19, 2018, and entitled "Decoupling Mechanism for Linear Surgical Stapler," the disclosure of which is incorporated herein by reference in its entirety.

As shown in FIG. 2, the linear surgical stapler (10) further includes a plurality of shrouds (56, 78) that cover select portions of the stapler (10) and facilitate effective gripping and manipulation of the stapler (10) by an operator during use. In this embodiment, the clamp lever shroud (56) is secured to and covers the outwardly facing side of the clamp lever (40) such that the clamp lever shroud (56) is configured to pivot with the clamp lever (40) relative to the cartridge channel (16). Additionally, the anvil shroud (78) is secured to and covers the outwardly facing side of the anvil channel (60). In some variations, the anvil shroud (78) can be coupled to the anvil channel (60) in accordance with the teachings of U.S. Patent Application No. 16/102,170, filed Aug. 13, 2018, and entitled "Clamping Assembly for Linear Surgical Stapler," the disclosure of which is incorporated herein by reference. In other variations, it will be understood that the shrouds (56, 78) can be coupled to the clamp lever (40) and the anvil channel (60) in a variety of other suitable ways that will be readily apparent to one of ordinary skill in the art.

As best seen in FIG. 3, the proximal end of the cartridge half (12) includes a retention assembly (80) configured to releasably retain the anvil half (14) and a portion of the firing assembly (100). The retention assembly (80) in this example includes an anvil latch member (82) and a detent member (84), both of which are rotatably coupled to the proximal end of the cartridge channel (16) via a laterally extending pin (86) located proximal to the firing slot (32). A torsion spring (340) (not shown) is configured to resiliently bias the anvil latch member (82) and the detent member in opposite rotational directions about a transverse axis defined by the pin (86).

The anvil latch member (82) includes an upper finger (88) configured to releasably capture the proximal anvil pin (70) when the pin (70) is guided into the proximal tapered notch (26) of the cartridge channel (16) thereby coupling the proximal ends of the stapler halves (12, 14). The lower end of the anvil latch member (82) defines a release button (90) configured to be depressed by an operator when the clamp lever (40) is in an open position to release the proximal pin (70) from the latch finger (88) thereby allowing the proximal ends of the stapler halves (12, 14) to be separated. The detent member (84) includes a distal finger (88) configured to releasably capture the proximal end of the sliding block (102) of the firing assembly (100) when the firing assembly (100) is in the proximal home position shown in FIG. The detent member (84) further includes a proximal hook (94) configured to releasably capture an upper end of the clamp lever latch member (54) while the sliding block (102) is positioned distally of its proximal home position, thereby preventing actuation of the clamp lever latch member (54) and opening of the clamp lever (40) during firing of the stapler (10). When the firing assembly (100) is in its proximal home position (i.e., before or after firing of the stapler (10)), the proximal hook (94) of the detent member (84) enables the clamp lever latch member (54) to rotatably disengage the proximal frame portion (18) of the cartridge channel (16) in response to actuation by an operator, so that the clamp lever (40) can then be opened. The retention assembly (80) and associated components of the cartridge half (12) may be further configured and operable in accordance with at least a portion of the teachings of U.S. Patent Application No. 16/102,164, filed August 13, 2018, entitled "Firing System for Linear Surgical Stapler," the disclosure of which is incorporated herein by reference.

As best seen in FIG. 4, the firing assembly (100) of the cartridge half (12) includes a slide block (102), a pair of actuators (104, 106) (or "firing knobs") pivotally coupled to the slide block (102), and a plurality of elongated beams (108, 112) extending distally from the slide block (102). The pair of side beams (108) are coupled at their proximal ends to a distal end of the slide block (102) and terminate distally in a pair of cam ramps (110). The cam ramps (110) are configured to engage the underside of the staple drivers (180) contained within the staple cartridge (130) (see FIG. 7) to actuate the staple drivers (180) upwardly, thereby driving (or "firing") the staples (170) from the cartridge (310) and into tissue clamped between the staple cartridge (310) and the anvil plate (72). The central beam (112) is connected to the side beams (108) via bridge elements (114) (or "knife blocks") that are spaced distally from the slide block (102). The central beam (112) terminates distally in a distally angled knife member (116) having a distal cutting edge (118) configured to cut tissue clamped between the distal portions of the stapler halves (12, 14). The distal portion of the central beam (112) further includes a locking element (120) that projects upwardly proximal to the knife member (116) and a lockout projection (122) that faces distally proximal to the locking element (120).

Each actuator (104, 106) of the firing assembly (100) is configured to be rotatable relative to the sliding block (102) between a deployed position and a retracted position such that only one actuator (104, 106) is deployed at a time, as described in more detail in U.S. Patent Application Publication No. 16/102,164, incorporated by reference above. In the deployed position, the actuators (104, 106) can be driven distally by an operator to actuate the firing assembly (100) distally through the stapler (10) to simultaneously cut and staple tissue clamped between the stapler halves (12, 14).

B. Exemplary Use of a Linear Surgical Stapler Figures 5A-5E illustrate an exemplary coupling of the stapler halves (12, 14) and subsequent firing of the assembled stapler (10) during a surgical procedure. As shown in Figure 5A, the clamp lever (40) of the cartridge half (12) is provided in an open position with the jaw slot (50) aligned with the vertical slot (24) of the cartridge channel side flange (22). Additionally, the firing assembly (100) is maintained in its proximal home position by the detent member (84) of the retaining assembly (80), as shown in Figure 3, discussed above. At this stage, a portion of tissue (not shown) to be stapled and severed can be positioned on the staple cartridge (130) disposed within the distal jaw portion (20) of the cartridge half (12). Alternatively, the tissue can be positioned on the staple cartridge (130) after coupling the proximal ends of the stapler halves (12, 14), as described below.

As shown in Figures 5A-5B, the proximal ends of the stapler halves (12, 14) are aligned with one another and the proximal anvil pin (70) is guided downwardly into the proximal tapered notch (26) of the cartridge channel (16) to engage the upper finger (88) of the anvil latch member (82). This engagement forces the anvil latch member (82) to resiliently rotate clockwise, causing the upper finger (88) of the anvil latch member (82) to capture the anvil pin (70), thereby releasably coupling the proximal ends of the stapler halves (12, 14) to one another, as seen in Figure 5B. As shown in FIG. 5C, with the clamp lever (40) in the open position, the anvil half (14) is rotated about the proximal anvil pin (70) toward the anvil half (14) such that the distal latch pin (68) of the anvil half (14) is received within the vertical slot (24) of the cartridge channel side flange (22) and the jaw slot (50) of the clamp lever (40). At this point, the distal jaw portions (20, 64) of the stapler halves (12, 14) are in a partially approximated state to allow for final adjustment prior to clamping the tissue received therebetween.

As shown in FIG. 5D, the clamp lever (40) is closed to draw the anvil latch pin (68) against the closed proximal end of the jaw slot (50), fully clamping the anvil half (14) against the cartridge half (12) and clamping tissue (not shown) between the staple cartridge (130) and the anvil plate (72). A slight lateral gap is defined between the staple cartridge (130) and the anvil plate (72) by the tissue gap post (146) of the staple cartridge (130) (see FIG. 6), which allows the tissue to be contained therebetween at a predetermined tissue compression. As shown in FIG. 6, the tissue gap post (146) is disposed at the distal end of the staple cartridge (130) and is configured to contact the distal end of the anvil plate (72) when the stapler (10) is in the fully clamped state shown in FIG. 5D.

Once the fully clamped condition is reached, as shown in FIG. 5E, the stapler (10) can be fired by driving the deployed actuators (104, 106) of the firing assembly (100) distally along the proximal frame portion (18) of the cartridge half (12). As described above in connection with FIG. 4, this action translates the elongated beams (108, 112) of the firing assembly (100) distally through corresponding channels formed in the staple cartridge (130), thereby firing staples into the clamped tissue by the cam ramps (110) and staple driver (180) while the knife member (116) cuts the clamped tissue. After completion of the firing stroke, the firing assembly (100) is returned to its proximal home position by the actuators (104, 106). The clamp lever latch member (54) is then depressed to release the proximal end of the clamp lever (40) from the cartridge channel (16), thereby allowing the clamp lever (40) to reopen. The release button (90) of the retaining assembly (80) can then be depressed to release the anvil half (14) from the cartridge half (12), thereby separating the stapler halves (12, 14) from one another, thereby releasing the newly stapled and severed tissue. It will be appreciated that in some variations, the stapler (10) can include a mechanism to facilitate separation of the stapler halves (12, 14) similar to the mechanism disclosed in U.S. Patent Application Publication No. 16/165,587, which is incorporated herein by reference.

II. Exemplary Staple Cartridge with Staple Driver and Tissue Gripping Features to Promote Proper Formation of Three-Dimensional Staples As described below in conjunction with Figures 15-16, the staple cartridge (130) of the linear surgical stapler (10) is configured to apply staples (170) having a three-dimensional ("3D") formed configuration in which the legs of each staple (170) are formed such that the leg tips are laterally offset from one another to provide a non-planar shaped formed staple (170). Such a staple configuration is advantageous in providing enhanced hemostasis as well as a uniform distribution of compressive force along the resulting staple line applied to the patient's tissue. Additionally, the staple cartridge (130) is provided with standoff members (152, 160, 162, 164) that enhance the ability of the staple cartridge (130) to effectively grasp tissue clamped between the staple cartridge (130) and the anvil plate (72) during the stapling and severing process described above. Accordingly, it may be desirable to appropriately shape certain features of staple cartridge (130) to provide appropriate clearance to promote proper 3D formation of staples (170) and prevent poor staple formation. Providing such clearance may also be advantageous in reducing the user input force required to distally actuate firing assembly (100) to fire staple cartridge (130).

Although the mechanisms shown and described below are illustrated in the context of a staple cartridge (130) of a linear surgical stapler (10), it will be understood that such mechanisms are also applicable to staple cartridges configured for use with various other types of surgical staplers.

A. Overview of an Exemplary Staple Cartridge As shown in Figures 6 and 7, the staple cartridge (130) includes an elongated cartridge body (132) and a plurality of staples (170) and staple drivers (180) housed within the cartridge body (132). A lockout bypass mechanism in the form of a swing tab (144) is rotatably coupled to a proximal end of the cartridge body (132) and will be described in more detail below. In some variations, the staple cartridge (130) can further include a bottom tray (not shown) that extends along the underside of the cartridge body (132) and aids in retaining the staples (170) and staple drivers (180) within the cartridge body (132).

With brief reference to FIG. 12, each staple (170) has a central crown (172) and a pair of legs (174) extending away from the crown (172) and having leg tips (176). In the unformed state of the staple (170), the crown (172) and legs (174) form a U-shape in which the leg tips (176) extend away from the crown (172), and the unformed staple (170) has a two-dimensional shape because the crown (172) and legs (174) lie in a common plane. With brief reference to FIGS. 15 and 16, in the 3D formed state of the staple (170), each leg (174) is bent by a corresponding staple forming pocket (74) in the anvil plate (72) such that each leg tip (176) extends toward the crown (172). More specifically, as shown in FIG. 16, each formed leg tip (176) is laterally offset from one another and from the crown (172) on either side of the crown (172), thereby providing the formed staple (170) with a three-dimensional shape with the functional advantages discussed above.

6 and 7, the cartridge body (132) of this embodiment extends linearly along the longitudinal axis between a proximal end having a pair of hooks (134) and a distal end having a tapered nose (136). The proximal hooks (134) are configured to releasably capture the pivot pin (42) of the clamp lever when the staple cartridge (130) is seated in the distal jaw portion (20) of the cartridge channel (16) and extend downwardly through a corresponding opening formed in the floor of the cartridge channel (16). A pair of wing-like tabs (138) disposed near the proximal end on the sides of the cartridge body (132) are configured to facilitate insertion and removal of the staple cartridge (130) from the distal jaw portion (20).

As best seen in FIGS. 6-9, the upper surface of the cartridge body (132) defines a deck (140). An elongated knife slot (142) extends longitudinally through the deck (140) along the longitudinal axis of the staple cartridge (130) and is configured to slidably receive the knife member (116) of the firing assembly (100) therethrough in response to distal actuation of the knife member as described above. A firing lockout bypass mechanism in the form of a swing tab (144) is rotatably coupled to the cartridge body (132) at the proximal end of the knife slot (142). The swing tab (144) is configured to rotate between a deployed position in which the swing tab (144) extends perpendicularly across the proximal end of the knife slot (142) and a retracted position in which the swing tab (144) extends parallel to the knife slot (142). As shown and described below in connection with FIGS. 27A-27B, in the deployed position, the swing tab (144) is configured to bias the firing assembly (100) from a locked out state to a fired state in which the firing beams (108, 112) can translate distally through the staple cartridge (130) to staple and sever tissue clamped by the stapler (10).

A rigid tissue gap post (146) is secured to the distal end of the knife slot (142) and projects upwardly away from the cartridge deck (140). The rounded upper end of the tissue gap post (146) is configured to contact the distal end of the anvil plate (72), thereby defining a tissue gap between the cartridge deck (140) and the anvil plate (72) when the stapler halves (12, 14) are clamped together as described above.

A pair of elongated ribs (148) extend along either side of the knife slot (142) and define raised surfaces projecting away from the deck (140). The elongated ribs (148) terminate at the proximal and distal ends of the knife slot (142) and are configured to promote a high grip of tissue along the knife slot (142), thereby stabilizing the tissue during cutting by the knife member (116). As shown in FIG. 11, the elongated ribs (148) of this variation have tapered distal ends disposed proximal to the tissue clearance post (146).

The cartridge body (132) of the staple cartridge (130) further includes a plurality of staple openings (150) extending transversely through the cartridge body (132) and opening into the deck (140). In this embodiment, the staple openings (150) are arranged in first and second parallel rows along either side of the knife slot (142), with the staple openings (150) in each row being longitudinally staggered relative to the staple openings (150) in adjacent rows. It will be appreciated that various suitable arrangements and quantities of staple openings (150) may be provided in other variations of the staple cartridge (130). Each staple cavity (150) is configured to receive a respective staple driver (180) and staple (170) therein. As discussed above, each cam ramp (110) of the firing assembly is configured to engage the underside of a staple driver (180) and actuate the staple driver (180) upwardly within the staple opening (150) to drive (i.e., "fire") the staple (170) from the staple opening (150) into tissue and against the anvil plate (72).

As best seen in FIGS. 8-11, the staple cartridge (130) further includes a plurality of tissue gripping members in the form of standoff members (152, 160, 162, 164) disposed on and projecting upwardly from the cartridge deck (140). The standoff members (152, 160, 162, 164) are distributed along the length of the deck (140) and are laterally offset from the knife slot (142) and the elongated rib (148) to align with and open to a respective one or more staple openings (150). As described below, the standoff members (152, 160, 162, 164) are configured to grip the tissue when the deck (140) and the anvil plate (72) are clamped together, thereby stabilizing the tissue, and further to optimize compression of the tissue at the staple location to facilitate effective stapling and severing of the tissue. In this variation, the standoff members (152, 160, 162, 164) are formed integrally with the cartridge body (132), but it will be understood that in other variations, the standoff members (152, 160, 162, 164) may be formed separately from the cartridge body (132) and connected to the cartridge body.

8-10, the first group of standoff members on the staple deck (140) are shown in the form of cleats (152) that are individually positioned in alignment with the staple openings (150) along the length of the knife slot (142). Each cleat (152) includes a pair of longitudinally opposing end features (154). In particular, a first end feature (154) opens into and partially surrounds an end portion of a first staple opening (150) in a given row of staple openings (150), and an opposing second end feature (154) opens into and partially surrounds an end portion of an adjacent second staple opening (150) in the same row of staple openings (150). The first and second end features (154) are connected together by a concave bridge feature (156).

Each end feature (154) of the cleat (152) has a generally U-shaped cross-section in a plane extending parallel to the deck (140) along the height of the cleat (152). Each end feature (154) also defines an inner wall that connects to and projects outwardly from the inner wall of the respective staple opening (150). In this manner, each end feature (154) opens into and communicates with the respective staple opening (150). Each end feature (154) is thus configured to guide the respective staple legs (174) of the corresponding staple (170) (see FIG. 12) and the respective staple driver (180) as the staple (170) is ejected upwardly from the staple opening (150) by the staple driver (180). Thus, each end formation (154) cooperates with the facing end feature (154) of the adjacent cleat (152) or with an end cap (160) (see FIG. 11) described below to provide guidance for such staples (170) and staple drivers (180).

As best seen in Figures 8 and 10, each end feature (154) of the cleat (152) tapers away from the deck (140) toward a respective concave bridge feature (156) along the height of the cleat (152), thereby providing each cleat (152) with a trapezoidal side cross-section. In this regard, as best seen in Figure 10, each end feature (154) includes an angled end surface (155) that slopes toward the concave bridge feature (156) and is rounded along its height. This rounded configuration of the angled end surface (155) allows each end feature (154) to face a respective staple leg (174) and respective staple driver (180), thereby effectively guiding the staples (170) and staple drivers (180) upward, while providing effective clearance to facilitate proper 3D formation of the staple legs (174). In particular, the rounded configuration of the angled end surface (155) reduces the risk of the tip of the staple leg (174) colliding with the end feature (154) as the staple leg (174) is formed by the anvil plate (72), which can lead to poor formation of the staple leg (174).

As shown in FIGS. 8 and 10, the laterally outermost rows of cleats (152) on the cartridge deck (140) of this embodiment are formed with outer sides having flat surfaces (158) that are angled relative to the length of the staple cartridge (130). Thus, these particular cleats (152) are asymmetric about their longitudinal axis, which may help facilitate the molding process for forming the cartridge body (132).

The cleats (152) in this embodiment are formed individually relative to one another such that each cleat (152) is independent and spaced apart from adjacent cleats (152), but in other variations, the cleats (152) may be interconnected to one another along one or more portions of the cartridge deck (140).

As shown in FIG. 11, the cartridge deck (140) includes additional standoff members in the form of proximally facing end caps (160) disposed at the distal ends of the rows of staple openings (150). In this variation, the proximal portion of each end cap (160) is shaped similarly to the cleat end features (154) described above. In particular, the proximal portion of each end cap (160) has a U-shape and partially wraps around the distal end portion of the respective staple openings (150). Thus, each end cap (160) cooperates with the facing end features (154) of the adjacent cleats (152) in the same row to guide the respective staples (170) and staple drivers (180) during firing of the staple cartridge (130). In this embodiment, each end cap (160) further includes a distal ramp feature (162) tapering distally toward the cartridge nose (136). A similar ramp mechanism (164) is positioned distal to and in longitudinal alignment with the tissue gap post (146). The ramp mechanisms (162, 164) are configured to facilitate smooth insertion of the distal end of the cartridge half (12) of the stapler (10) into or beneath the tissue structure without tissue catching or otherwise adhering to the cleat (152), end cap (160), or tissue gap post (146).

In this embodiment, the standoff members (152, 160, 162, 164) protrude from the cartridge deck (140) at a uniform maximum height, thus collectively defining a raised tissue-engaging surface. In other variations, the standoff members (152, 160, 162, 164) may protrude from the cartridge deck (140) at different heights, thus defining two or more raised tissue-engaging surfaces.

12-14 show an exemplary pair of staple drivers (180) of the staple cartridge (130). In this embodiment, each pair of staple drivers (180) is integrally formed as a driver unit (181) having bridge elements (182) that interconnect the staple drivers (180) at their lower ends (186). The staple drivers (180) of the driver unit (181) are arranged in a staggered manner that is laterally and longitudinally offset from one another relative to the longitudinal axis of the staple cartridge (130) such that the staple drivers (180) are configured to align with corresponding staple openings (150) in the cartridge body (132). As shown in FIG. 12, each staple driver (180) includes an upper end (184), a lower end (186), a first side (188), and an opposite second side (190). As seen in FIG. 14, the staple driver (180) of this embodiment has a cross-section formed along its height with an elongated octagonal shape that defines first and second sides (188, 190). The upper end (184) of the staple driver (180) includes a groove (192) configured to receive and support the crown (172) of a corresponding staple (170).

Each staple driver (180) in this embodiment is formed with pockets (194a, 194b) opening at the top end (184) and configured to receive the staple leg tips (176) when the staple legs (174) are formed by the anvil plate (72) when the stapler (10) is fired. In particular, the first side (188) of the driver (180) includes a first pair of adjacent pockets (194a) at the top end (184) and the second side (190) includes a second pair of adjacent pockets (194b) at the top end (184). In this variation, the pockets (194a, 194b) have a uniform shape and are symmetrically arranged such that each pocket (194a) on the first side (188) is aligned with the opposite pocket (194b) on the second side (190).

Each pocket (194a, 194b) of the staple driver (180) is defined by a respective chamfered surface (196) on the top end (184) and is separated from an adjacent pocket (194a, 194b) on the same side (188, 190) by a boss (198) centrally located on each side (188, 190). Each chamfered surface (196) is angled toward the groove (192) such that the pockets (194a, 194b) on the first side (188) and the pockets (194a, 194b) on the second side (190) are angled toward each other at their top ends. Each pocket (194a, 194b) tapers in width toward the bottom end (186) and thus has a generally trapezoidal shape. In contrast, each boss (198) tapers in width toward the top end (184) and thus has a generally triangular shape. Additionally, each boss (198) defines an inner sidewall of each corresponding pocket (194a, 194b) near the center of the upper groove (192), while each pocket (194a, 194b) opens to an opposite side near the corresponding end of the upper groove (192). The bosses (198) are configured to aid in proper seating of the staple crown (172) within the upper groove (192) during assembly of the staple cartridge (130).

As shown in FIG. 15, each pocket (194a, 194b) of the staple driver (180) is configured to receive a staple leg tip (176) during formation of the staple (170) such that each staple leg tip (176) faces (but does not necessarily contact) a respective chamfered surface (196) of the staple driver (180). As a result, and advantageously, the provision of the pockets (194a, 194b) on the staple driver (180), in combination with the rounded and angled end surfaces (155) of the cleat (152) discussed above, allows for proper 3D formation of the staple (170) without the staple legs (174) striking the sides of the staple driver (180) or the end features (154) of the cleat (152) in a manner that would cause the staple (170) to be poorly formed.

As shown in FIG. 15, the first leg tip (176) of the staple (170) is received within a pocket (194a) on a first side (188) of the driver (180) during 3D staple formation. Similarly, the second leg tip (176) is received within a pocket (194b) on a second side (190) diagonally opposite from the first pocket (194a). Thus, the remaining pocket (194a) on the first side (188) and the remaining pocket (194b) on the second side (190) diagonally opposite are left unused in this embodiment. However, it will be appreciated that the provision of a pair of pockets (194a, 194b) on each side (188, 190) of the staple driver (180) allows the staple driver (180) to accommodate alternative configurations of the staple forming pockets (74) of the anvil plate (72) and the resulting 3D formed configurations of the staples (170). For example, in some variations, at least some of the staple forming pockets (74) of the anvil plate (72) can alternatively be configured to direct the staple legs (174) into an unused pair of diagonally opposed pockets (194a, 194b) shown in FIG. 15. Thus, each staple driver (180) is configured to accommodate the formation of staples (170) having a 3D configuration that is a mirror image of the 3D configuration shown in FIG. 16.

B. Exemplary Alternative Staple Drivers for a Staple Cartridge In some applications, it may be desirable to alternatively configure the staple cartridge (130) to accommodate firing into patient tissue of different thicknesses. For example, the dimensions of the cartridge deck (140) and standoff members (152, 160, 162, 164) can alternatively be configured to accommodate stapling of relatively thin tissue, such as, for example, tissue of a vasculature. In such alternative variations of the staple cartridge (130), the staples (170) can have a slightly different 3D formed shape relative to the staple shape shown in FIG. 16. For example, the staple legs (174) can be formed such that the formed staples (170) have a smaller formed height (e.g., approximately 0.035 inches to 0.040 inches) and the leg tips (176) are positioned closer to the center of the crown (172) than the ends of the crown (172), as shown in FIG. 20. As a result, pockets (194a, 194b) and bosses (198) of staple driver (180) may permit slight reconfiguration to accommodate such differences in the 3D formation of staples (170) without undesirable collision of staple legs (174) against the mechanisms of staple driver (180), which may lead to poor staple formation and a resultant increase in the user input force required to fire surgical stapler (10). Such exemplary variations of staple driver (180) are described in more detail below.

17-19 show another exemplary pair of staple drivers (200) configured for use with staple cartridge (130). Staple cartridge (200) is similar to staple cartridge (180) described above, except as described below. Like staple driver (180), staple drivers (200) are integrally formed as a driver unit (201) having bridge elements (202) interconnecting staple drivers (200) at their lower ends (206) such that staple drivers (200) are arranged in a staggered configuration. Additionally, each staple driver (200) has a top end (204), a bottom end (204), a first side (208), an opposing second side (210), a groove (212) at the top end (204), and a transversely elongated octagonal shape along its height.

Unlike staple driver (180), each side (208, 210) of staple driver (200) includes a single pocket (194) configured to receive a staple leg (174) during formation of staple (170). Each pocket (194) is centrally positioned relative to upper groove (212) and is defined at its upper end by a corresponding chamfered surface (216) angled toward groove (212). Each chamfered surface (216) is bounded on two sides by a pair of bosses (218), each of which is offset an equal distance from the center of upper groove (212) along the length of groove (212). Each boss (218) defines a respective sidewall of a corresponding pocket (194), and the bosses (218) are shaped to provide each chamfered surface (216) with a generally rectangular shape. Additionally, each boss (218) has chamfered sides that taper along its height in a direction toward the top end (204). Each side (208, 210) of the staple driver (200) further includes a pair of side relief cuts that abut the outer side of the boss (218) and define triangular surfaces (220) that are coplanar with the respective chamfered surfaces (216).

As shown in FIG. 20, each pocket (194) is configured to receive a respective leg tip (176) of the staple (170) during 3D formation of the staples by the staple forming pockets (74) of the anvil plate (72). Similar to the pockets (194a, 194b) of the staple driver (180), the pockets (214) of the staple driver (200) are configured to receive the leg tips (176) of the staples such that the leg tips (176) face (but do not necessarily contact) the chamfered surface (216). Thus, the staple driver (200) is configured to facilitate proper 3D formation of the staples (170) in tissue, such as relatively thin tissue where a formed staple height of approximately 0.035 inches to 0.040 inches is desired.

III. Exemplary Mechanisms for Minimizing Plastic Deformation of a Firing Lockout Spring of a Linear Surgical Stapler As discussed above, the firing assembly (100) of the linear surgical stapler (10) is translatable distally within the cartridge channel (16) from a proximal home position (see FIG. 5D) to a distal fired position (see FIG. 5E) to simultaneously staple and sever tissue clamped between the distal portions of the stapler halves (12, 14). As described in more detail below, the cartridge half (12) further includes a resilient lockout member (250) in the form of a leaf spring configured to bias the firing assembly (100) toward a locked state when an unfired (i.e., "unused") staple cartridge (130) is not present within the distal jaw portion (20) of the cartridge half (12). When an unused staple cartridge (130) is seated within cartridge half (12), lockout spring (250) is biased downwardly by deployed swing tabs (144) of staple cartridge (130), thereby transitioning firing assembly (100) to the fired state. In the fired state, firing assembly (100) is free to actuate distally on biased lockout spring (250), thereby firing stapler (10). After firing is completed, firing assembly (100) can be retracted proximally to its home position, returning lockout spring (250) to its initial state and biasing firing assembly (100) to the locked state until the spent staple cartridge (130) is replaced with an unused staple cartridge (130).

When the firing assembly (100) is actuated distally during the firing stroke, it compresses the lockout spring (250) toward the floor of the cartridge channel (16). In some cases, this compression can cause plastic deformation of the lockout spring (250), which can unnecessarily impede the ability of the lockout spring (250) to operate effectively upon subsequent firing of the stapler (10). Therefore, it may be desirable to provide a mechanism in the cartridge half (12) of the stapler (10) that minimizes the risk of such plastic deformation.

As shown in FIG. 21, the underside of the sliding block (102) of the firing assembly (100) includes a first recess (124) that opens to the distal end of the sliding block (102) and extends proximally. Additionally, the underside of the bridge element (114) includes a second recess (126) that extends through the entire axial thickness of the bridge element (114). As described below, these underside recesses (124, 126) are configured to receive a portion of the lockout spring (250) when the firing assembly (100) is actuated distally to the fully fired state, thereby helping to reduce the amount that the lockout spring (250) is deflected during the firing stroke.

A. Exemplary Firing Lockout Systems for a Linear Surgical Stapler As shown in Figures 22-24, the cartridge half (12) of the linear surgical stapler (10) includes a firing lockout system including a guide block (230) (also referred to as a "spacer block") and a lockout spring (250). The guide block (230) is secured to the floor (34) of the cartridge channel (16) in general alignment with the distal slot (24) via a clamp lever pivot pin (42) that extends laterally through an opening formed in the guide block (230).

As shown in FIG. 23, the guide block includes a proximal body portion (232) having a first lateral width and a distal body portion (234) having a second, narrower width. A central slot (236) extends longitudinally through the proximal and distal body portions (232, 234) along a centerline of the guide block (230) and is configured to slidably receive a central beam (112) of the firing assembly (100) therethrough. As shown in FIG. 22, a distal portion of the central slot (236) opens through a top surface of the distal body portion (234) and is configured to slidably receive a knife member (116). A pair of side slots (238) extend longitudinally through the proximal body portion (232) along either side of the central slot (236) and are configured to slidably receive a side beam (108) of the firing assembly (100) therethrough. As best seen in FIGS. 23 and 27A-27C, the proximal body portion (232) further includes a lower channel (240) extending longitudinally along the lower end of the central slot (236). As described in more detail below, the lower channel (240) is sized with a lateral dimension suitable for permitting upward deflection of the base arm (252) of the lockout spring (250) within the lower channel (240) upon firing of the stapler (10). The distal body portion (234) includes a pair of laterally opposed recesses (242) configured to receive and retain a pair of distal anchor clips (258) of the lockout spring (250).

As best seen in FIG. 23, the lockout spring (250) is shown in the form of a leaf spring (254) having a flat base arm (252) and a downwardly curved tip (256) extending proximally from the base arm (252) at an upward angle. A pair of anchor clips (258) extend upwardly from the distal end of the base arm (252). As shown in FIGS. 23 and 27A-27C, the anchor clips (258) grip the distal body portion (234) within the distal recess (242), and the base arm (252) extends along the underside of the distal body portion (234), past the clamp lever pivot pin (42), and through the lower channel (240) of the proximal body portion (232). Angled spring legs (254) extend proximally from the lower channel (240) in longitudinal alignment with the central slot (236).

As shown in FIG. 25 and FIG. 27A-C, the central beam (112) of the firing assembly (100) is longitudinally positioned on the spring legs (254) of the lockout spring (250), and the central beam (112) is configured to translate directly on the spring legs (254). FIG. 26 shows an exemplary alternative lockout spring (260) similar to the lockout spring (250), except that the lockout spring (260) includes a downwardly curved proximal tip (266) that is wider than at least the intermediate and distal portions of the spring legs (264). The wider tip (266) is configured to maintain the central beam (112) in engagement with the spring legs (264) throughout the longitudinal actuation of the firing assembly (100).

As shown in FIG. 27A, in the absence of an unused staple cartridge (130) from the cartridge channel (16), the spring legs (254) resiliently bias the central beam (112) upward, causing the lockout projection (122) of the central beam (112) to engage the proximal face (233) of the guide block (230). This engagement locks the central beam (112) longitudinally relative to the guide block (230), thus preventing distal translation of the firing assembly (100). FIG. 27B illustrates how the central beam (112) is pivoted downward toward the cartridge channel floor (34) when an unused staple cartridge (130) is seated within the cartridge channel (16). It will be appreciated that in FIGS. 27B and 30B, an unused staple cartridge (130) is illustrated by a schematic depiction of the swing tab (144) in the deployed position. As described above, the swing tab (144) in the deployed position extends across the knife slot (142) of the staple cartridge (130). Thus, with an unused staple cartridge (130) seated in the cartridge channel (16), the swing tab (144) engages the upper surface of the central beam (112) between the knife member (116) and the locking element (120) to drive the central beam (112) downward to provide the firing assembly (100) in a fired state. Thus, with an unused staple cartridge (130) seated in the cartridge channel (16), the spring leg (254) of the lockout spring (250) is compressed downward toward the cartridge floor (34).

As shown in FIG. 27C, the fired firing assembly (100) is then driven distally by the actuators (104, 106) of the sliding block (102) (see FIG. 4). This pushes the firing beams (108, 112) to translate distally through the guide block (230) and into the staple cartridge (130), thereby actuating the staple driver (180) upwardly to drive the staples (170) into tissue while simultaneously severing the tissue with the knife member (116). As the firing assembly (100) advances distally over the spring legs (254) toward the fully fired position shown in FIG. 27C, the spring legs (254) are received through the underside recesses (126) of the bridge element (114) and into the underside recesses (124) of the sliding block (102). Additionally, the spring arm tip (256) is received within an opening (36) formed in the floor (34) of the cartridge channel. At the same time, the base arm (252) of the lockout spring (250) is allowed to resiliently bias upward within the lower channel (240) of the guide block (230) while the spring leg (254) is allowed to slide longitudinally as required within the lower recesses (124, 126) of the firing assembly (100). In this manner, the lockout spring (250) is allowed to assume a biased state that minimizes plastic deformation of the lockout spring in the fully fired state of the firing assembly (100).

B. Exemplary Alternative Firing Lockout Systems In some cases, it may be desirable to alternatively configure the above-described guide block (230) in other manners suitable for reducing plastic deformation of the lockout spring (250) when the linear surgical stapler (10) is fired. Figures 28-30C illustrate a cartridge half (12) with an exemplary alternative guide block (270) (or "spacer block") similar to the above-described guide block (230), except as described below. In this regard, it will be appreciated that a firing lockout system for the linear surgical stapler (10) can be defined by replacing the guide block (270) with the guide block (230) and other components of the cartridge half (12) described above that cooperate with the lockout spring (250).

The guide block (270) is secured to the cartridge channel floor (34) and has a proximal body portion (272) having a first lateral width, a distal body portion (274) having a second narrower width, a central slot (276) extending longitudinally through the proximal and distal body portions (272, 274), and a pair of side slots (278) extending longitudinally through the proximal body portion (272) along either side of the central slot (276). The proximal body portion (272) further includes a lower channel (280) extending longitudinally along a lower end of the central slot (276). The distal body portion (274) includes a pair of laterally opposed recesses (282) configured to receive and retain the distal anchor clip (258) of the lockout spring (250).

As shown in FIG. 30A, the proximal body portion (272) includes a pair of spring support elements (284) that project laterally inward from opposing walls of the lower channel (280) proximal to the clamp lever pivot pin (42). A base arm (252) of the lockout spring (250) extends longitudinally through the lower channel (240) such that the base arm (252) contacts and is vertically supported by the clamp lever pivot pin (42) and the spring support elements (284).

An elongated proximal member (286) is integrally joined to the proximal body portion (272) of the guide block (270) and extends proximally along the cartridge channel floor (34) in the proximal frame portion (18) of the cartridge channel (16). An upper surface of the elongated proximal member (286) has an elongated recess (288) in communication with the lower channel (280) and configured to receive therein the spring leg (254) of the lockout spring (250) as the spring leg (254) is biased downwardly upon firing of the stapler (10). The proximal end of the elongated proximal member (286) can include a user gripping mechanism (not shown) that projects downwardly through an opening in the cartridge channel floor (34). Such a user gripping mechanism may be configured to act as a fulcrum for the user's fingers, allowing the user to use the corresponding thumb of the same hand to distally depress the release button (90) of the retention assembly (80) described above.

An elongated distal member (290) is integrally joined to the distal body portion (274) of the guide block (270) and extends distally along the cartridge channel floor (34) within the distal jaw portion (20) of the cartridge channel (16). The distal end of the elongated distal member (290) may include a mechanical grounding mechanism (not shown) configured to axially secure the elongated distal member (290) relative to the distal jaw portion (20) of the cartridge channel (16). As shown in FIGS. 30A-30C and described below, the firing assembly (100) is configured to translate over the elongated proximal and distal members (286, 290) through the guide block (270).

As shown in FIG. 30A, in the absence of an unused staple cartridge (130) from the cartridge channel (16), the spring legs (254) resiliently bias the central beam (112) upwardly, such that the lockout projections (122) of the central beam (112) engage the proximal surface (273) of the proximal body portion (272) of the guide block (270). This engagement places the firing assembly (100) in a locked out state similar to that described above in connection with FIGS. 27A-27C. FIG. 30B illustrates how the central beam (112) is pivoted downwardly toward the elongated proximal member (286) by the deployed swing tabs (144) of the unused staple cartridge (130) when seated in the cartridge channel (16), thereby placing the firing assembly (100) in a fired state. When the unused staple cartridge (130) is seated, the spring legs (254) of the lockout spring (250) are also compressed downward toward the elongated proximal member (286).

As shown in FIG. 30C, the fired firing assembly (100) is then driven distally, which pushes and translates the firing beams (108, 112) distally through the guide block (270) and into the staple cartridge (130), thereby actuating the staple driver (180) upwardly to drive the staples (170) into tissue while simultaneously severing the tissue with the knife member (116). As the firing assembly (100) advances distally over the spring legs (254) toward the fully fired position shown in FIG. 30C, the spring legs (254) are received through the underside recesses (126) of the bridge element (114) and into the underside recesses (124) of the slide block (102), in a manner similar to that described above in connection with FIGS. 27A-27C. Further, the spring leg (254) and its proximal tip (256) are received in the elongated recess (288) of the elongated proximal member (286). At the same time, as shown in FIG. 30, the intermediate portion of the base arm (252) of the lockout spring (250) is vertically supported by one or both of the clamp lever pivot pin (42) and the spring support element (284), while the proximal portion of the base arm (252) can be elastically biased within the lower channel (280) of the guide block (270). In this manner, the lockout spring (250) can assume a biased state that minimizes plastic deformation of the lockout spring in the fully fired state of the firing assembly (100).

IV. Exemplary Mechanisms for Promoting Uniform Formed Staple Height In some cases, when the anvil half (14) of the linear surgical stapler (10) is clamped against the cartridge half (12) by closure of the clamp lever (40), the distal jaw portion (64) of the anvil channel (60) can deform along its length relative to the cartridge half (12). More specifically, such deformation can cause the anvil plate (72) and corresponding sidewall mounting surfaces of the distal jaw portion (64) to assume a convex curvature relative to the staple cartridge deck (140) of the cartridge half (12), as shown, for example, in FIG. 34, which illustrates an exaggerated curvature of the distal jaw portion (64) for illustrative purposes. As a result, the longitudinally extending tissue gap formed between the staple cartridge deck (140) and the anvil plate (72) can be inconsistent in size along the length of the staple cartridge (130) and the anvil plate (72). In particular, the tissue gap may be smaller at an intermediate location of the staple cartridge (130) and anvil plate (72) and larger at the proximal and distal ends of the staple cartridge (130) and anvil plate (72), as shown, for example, in FIG. 34. Such inconsistencies in tissue gap size may result in inconsistent heights of staples (170) formed in the clamped tissue, which may be undesirable. Accordingly, it may be desirable for the anvil half (14) and/or cartridge half (12) to include features that accommodate such deflections of the anvil channel (60) and ensure consistency in the formed height of staples (170) along the length of the staple cartridge (130) and anvil plate (72).

A. Exemplary Anvil Half with a Curved Anvil Plate Figures 31-33B show another exemplary anvil half (300) that is similar to the anvil half (14) described above, except as noted below. As shown in Figure 31, the anvil half (300) includes an anvil channel (302) having a distal jaw portion (304) with a pair of side walls that define a pair of concavely curved mounting surfaces (306) to which an anvil plate (308) is attached. The anvil plate (308) itself conforms to the concavely curved mounting surfaces (306) of the anvil channel (302) such that the mounting surfaces (306) and the anvil plate (308) extend longitudinally along the same concavely curved path.

In some variations, the anvil plate (308) may be initially formed in a straight, flat configuration and then deformed into a curved configuration when compressed against the curved mounting surface (306) of the anvil channel (302) and secured (e.g., by welding) to the mounting surface during manufacture of the anvil half (302). In other variations, the anvil plate (308) may be preformed with the same concave curvature as the mounting surface (306) before being secured to the curved mounting surface (306). In either case, the concave curvature of the curved mounting surface (306), and therefore the anvil plate (308), is selected as the inverse of the convex curvature that the distal jaw portion (304) is expected to assume relative to the staple cartridge deck (140) of the cartridge half (12) when the stapler halves (12, 300) are fully clamped together.

As shown in FIG. 31, the concave curvature of the mounting surface (306) and the anvil plate (308) in this variation is non-uniform along the length of the distal jaw portion (304). Thus, the transverse height defined by the combination of the distal jaw portion (304) and the anvil plate (308) varies non-uniformly along the length of the distal jaw portion (304). In particular, as shown in FIGS. 32A-32C, the anvil half (302) has a minimum transverse height (H1) at the midpoint of the distal jaw portion (304), a maximum transverse height (H2) at the distal end of the distal jaw portion (304), and an intermediate transverse height (H3) at the proximal end of the distal jaw portion (304). In some other variations, the distal and proximal transverse heights (H2, H3) may be equal.

33A shows the anvil half (302) in a partially clamped state against the cartridge half (12) described above. In this state, the distal end of the anvil plate (308) begins to clamp against the tissue gap post (146) of the cartridge half (12), while the anvil plate (308) and mounting surface (306) of the anvil half (300) are still in a concavely curved configuration against the deck (140) of the staple cartridge (130). As shown in FIG. 33B, when the clamp lever (40) is closed to its fully closed position, the distal jaw portion (304) of the anvil channel (302) is slightly deformed along its length distal to the latch pin (307). This deformation flattens the mounting surface (306) of the anvil half (302) and the anvil plate (308) while simultaneously forming a concave curvature on the upper surface (309) of the distal jaw portion (304). As a result, the anvil plate (308) extends parallel to the cartridge deck (140), thus defining a uniform tissue gap (G) therebetween along its length. This uniform tissue gap (G) promotes the formation of staples (170) having a uniform height along the length of the anvil plate (308) and the cartridge deck (140).

B. Exemplary Staple Cartridge with Staple Drivers of Different Heights FIG. 34 illustrates a schematic of anvil channel (60) in a fully clamped state relative to another exemplary staple cartridge (310). Staple cartridge (310) is similar to staple cartridge (130) described above, except that staple cartridge (310) includes a plurality of staple drivers (312a, 312b, 312c) having different heights (H1, H2, H3) along the length of staple cartridge (310). Specifically, in this variation, a middle portion of staple cartridge (310) includes staple driver (312a) of a minimum height (H1), a distal end of staple cartridge (310) includes staple driver (312b) of a maximum height (H2), and a proximal end of staple cartridge (310) includes staple driver (312c) of an intermediate height (H3). In some other variations, the heights (H2, H3) of the distal and proximal staple drivers (312b, 312c) may be equal. Although not shown in the figures, it will be appreciated that the height of the staple drivers positioned between the distal driver (312b) and the middle driver (312a) can be gradually changed from the distal driver height (H2) to the middle driver height (H1). Similarly, the height of the staple drivers positioned between the middle driver (312a) and the proximal driver (312c) can be gradually changed from the middle driver height (H1) to the proximal driver height (H3).

As shown in FIG. 34 and described above, the distal jaw portion (64) of the anvil channel (60) bends convexly toward the staple cartridge (310) when clamped against the cartridge half (12). As a result, the distal jaw portion (64) of the anvil channel (60) assumes a curved condition that provides a varying tissue gap between the anvil plate (72) and the staple cartridge (310) along its length. In particular, the intermediate portion of the anvil plate (72) defines a minimum tissue gap (G1), the distal end of the anvil plate (72) defines a maximum tissue gap (G2), and the proximal end of the anvil plate (72) defines an intermediate tissue gap (G3). Providing staple drivers (312a, 312b, 312c) of different heights (H1, H2, H3) compensates for such variations in tissue gaps (G1, G2, G3) by driving the staples (170) at shorter distances in the middle of the cartridge (310) and gradually greater distances in the proximal and distal directions. As a result, staples (170) are formed with a uniform height along the entire length of the staple cartridge (310) despite the curvature of the anvil channel (60) and non-uniformities in the tissue gaps (G1, G2, G3).

V. Exemplary Combinations The following examples relate to various non-exhaustive methods in which the teachings herein may be combined or applied. It should be understood that the following examples are not intended to limit the scope of any claims that may be presented at any time in this application or in a later filing of this application. No disclaimer is intended. The following examples are provided for illustrative purposes only. It is contemplated that the various teachings herein may be configured and applied in many other ways. It is also contemplated that certain features mentioned in the following examples may be omitted in some variations. Thus, none of the aspects or features mentioned below should be considered as critical unless expressly indicated to be so at a later date by the inventors or by the inventors' successors in interest. If any claim is presented in this application or in a later filing related to this application that includes additional features other than those mentioned below, those additional features should not be presumed to have been added for any reason related to patentability.

A staple cartridge configured for use with a surgical stapler, comprising: (a) a cartridge body; (b) a deck defined by the cartridge body, the deck configured to compress tissue against an anvil of the surgical stapler; (c) a plurality of staple openings formed in the deck; (d) a plurality of staples disposed in the staple openings, each of the staples including a pair of legs; and (e) a plurality of staple drivers disposed in the staple openings, operable to drive the staples through the tissue and against the anvil to form the legs, each of the staple drivers including: (i) a driver body; (ii) a first pocket disposed on a first side of the driver body; and (iii) a second pocket disposed on a second side of the driver body, the first pocket and the second pocket configured to receive the legs of a respective staple when the legs are formed against the anvil.

A staple cartridge as described in Example 1, in which the first pocket and the second pocket open to the upper end of the driver body.

The staple cartridge of Example 1 or 2, wherein each of the staple drivers further includes a first boss disposed on a first side of the driver body and a second boss disposed on a second side of the driver body, the first boss defining a sidewall of the first pocket and the second boss defining a sidewall of the second pocket.

A staple cartridge according to any one of Examples 1 to 3, wherein the first pocket is defined by a first chamfered surface on a first side of the driver body and the second pocket is defined by a second chamfered surface on a second side of the body.

The staple cartridge of Example 4, wherein the upper portions of the first chamfered surface and the second chamfered surface are angled toward each other.

The staple cartridge according to any one of Examples 1 to 5, further comprising a plurality of standoff members disposed on the deck, the standoff members configured to protrude in a direction away from the deck and engage tissue.

The staple cartridge of Example 6, wherein at least some of the standoff members each include an end portion that circumscribes a portion of the adjacent staple opening.

The staple cartridge of Example 7, wherein the end portions include rounded end faces configured to face respective ones of the staple drivers when the staple drivers are actuated.

A staple cartridge according to any one of Examples 6 to 8, wherein the standoff member includes a ramp mechanism disposed at the distal end of the deck.

The staple cartridge of Example 9 further comprises a post disposed at a distal end of the deck, and the ramp mechanism is disposed distal to and longitudinally aligned with the post along the longitudinal axis of the staple cartridge.

The staple cartridge according to any one of Examples 1 to 10, further comprising: (a) an elongated slot formed in the deck configured to slidably receive a cutting member passing therethrough, the staple opening being aligned with the elongated slot; and (b) a pair of elongated ribs disposed on the deck, the pair of elongated ribs extending longitudinally along opposing sides of the elongated slot.

A staple cartridge according to any one of Examples 1 to 11, in which the cartridge body extends linearly along the longitudinal axis.

A surgical stapler comprising: (a) a first stapler half having a first distal portion supporting an anvil; (b) a second stapler half having a second distal portion; and (c) a staple cartridge according to claim 1, wherein the second distal portion is configured to receive the staple cartridge, and the first stapler half and the second stapler half are releasably coupled to each other to clamp tissue between the anvil and the staple cartridge.

The surgical stapler of Example 13, wherein each of the staples includes a crown from which a pair of legs extend, and the anvil is configured to form the legs of the staples such that when the legs are formed, the leg tips of each staple are laterally offset from each other and from the crown on either side of the crown.

The surgical stapler according to embodiment 13 or 14, wherein the second stapler half includes (i) a firing assembly selectively operable in a distal direction to actuate the staple driver to drive the staple from the staple opening, through the tissue and against the anvil, the underside of the firing assembly having a recess, and (ii) a resilient member, the resilient member configured to bias the firing assembly to a locked state when the staple cartridge is not present in the second distal portion, thereby preventing distal actuation of the firing assembly, and when the staple cartridge is initially seated within the second elongate member, the firing assembly is configured to assume a fired state in which the firing assembly is translatable in a distal direction over the resilient member in the oriented state, such that a portion of the resilient member is received within the recess of the firing assembly.

The surgical stapler of Example 15, wherein the second stapler half further includes a guide member having a channel, the elastic member extending longitudinally through the channel, and the elastic member configured to elastically deflect within the channel when the firing assembly is advanced distally.

A staple cartridge configured for use with a surgical stapler, comprising: (a) a cartridge body; (b) a deck defined by the cartridge body, the deck configured to compress tissue against an anvil of the surgical stapler; (c) a plurality of staple openings formed in the deck; (d) a plurality of staples disposed within the staple openings, each of the staples including a first leg and a second leg; and (e) a plurality of staple drivers disposed within the staple openings, the plurality of staples configured to drive the staple through the tissue. and a plurality of staple drivers operable to drive staples against the anvil to form the legs, each of the staple drivers including (i) a first side having a first chamfered surface and (ii) a second side having a second chamfered surface, the first chamfered surface configured to receive the first leg of a respective staple in a facing arrangement and the second chamfered surface configured to receive the second leg of a respective staple in a facing arrangement when the first and second legs are formed against the anvil.

The staple cartridge of Example 17, wherein the upper end of each staple driver is configured to support a respective staple, and the first chamfered surface and the second chamfered surface extend to the upper end.

A surgical stapler comprising: (a) a first elongated member having a distal portion that supports an anvil; (b) a second elongated member having a distal portion configured to receive a staple cartridge, the first elongated member and the second elongated member being releasably coupled to one another to clamp tissue between the anvil and the staple cartridge; (c) a guide member secured to the second elongated member; (d) a resilient member secured to the guide member; and (e) a firing assembly slidably coupled to the second elongated member, the lower surface of the firing assembly including a recess. A surgical stapler, the guide member being configured to guide translation of a portion of the firing assembly relative to the second elongated member, the resilient member being configured to bias the firing assembly to a locked out state when a staple cartridge is not present on the second elongated member, thereby preventing distal actuation of the firing assembly, and when an unused staple cartridge is seated within the second elongated member, the firing assembly being configured to assume a fired state in which the firing assembly is distally translatable on the resilient member in a deflected state such that a proximal end of the resilient member is received within a recess in the firing assembly.

The surgical stapler of Example 19, wherein the elastic member extends longitudinally through the guide member, and the elastic member is configured to elastically deflect within the guide member when the firing assembly is advanced distally.

VI. Other It should be understood that any one or more of the teachings, expressions, embodiments, examples, etc. described herein can be combined with any one or more of the other teachings, expressions, embodiments, examples, etc. described herein. Thus, the above teachings, expressions, embodiments, examples, etc. should not be considered independently of each other. Various suitable ways in which the teachings of this specification can be combined will be readily apparent to those skilled in the art in light of the teachings of this specification. Such modifications and variations are intended to be included within the scope of the claims.

Furthermore, any one or more of the teachings, expressions, embodiments, examples, etc. described herein may be implemented in accordance with U.S. patent application Ser. No. 15/889,363, filed Feb. 6, 2018, and entitled "Release Mechanism for Linear Surgical Stapler"; U.S. patent application Ser. No. 15/889,370, filed Feb. 6, 2018, and entitled "Lockout Assembly for Linear Surgical Stapler"; U.S. patent application Ser. No. 15/889,370, filed Feb. 6, 2018, and entitled "Features to Align and Close Linear Surgical Stapler"; U.S. patent application Ser. No. 15/889,374, filed Feb. 6, 2018, entitled "Releasable Coupling Features for Proximal Portions of Linear Surgical Stapler"; U.S. patent application Ser. No. 15/889,376, filed Feb. 6, 2018, entitled "Firing Lever Assembly for Linear Surgical Stapler"; U.S. patent application Ser. No. 15/889,388, filed Feb. 6, 2018, entitled "Clamping Mechanism for Linear Surgical Stapler"; U.S. patent application Ser. No. 15/889,390, entitled "Firing System for Linear Surgical Stapler," filed Aug. 13, 2018; U.S. patent application Ser. No. 16/102,164, entitled "Firing System for Linear Surgical Stapler," filed Aug. 13, 2018; U.S. patent application Ser. No. 16/102,170, entitled "Clamping Assembly for Linear Surgical Stapler," filed Oct. 11, 2018; No. 16/157,599, entitled "Closure Assembly for Linear Surgical Stapler," filed Oct. 11, 2018; and/or U.S. patent application Ser. No. 16/165,587, entitled "Decoupling Mechanism for Linear Surgical Stapler," filed Oct. 19, 2018. The disclosures of each of these applications are incorporated herein by reference.

Any patent, publication, or other disclosure referred to as being incorporated by reference herein, in whole or in part, is to be understood as being incorporated herein only to the extent that the incorporated content does not conflict with current definitions, views, or other disclosures set forth in this disclosure. As such, and to the extent necessary, the disclosures expressly set forth herein shall take precedence over any conflicting statements incorporated herein by reference. Any content, or portions thereof, referred to as being incorporated by reference herein but which conflicts with current definitions, views, or other disclosures set forth herein shall be incorporated only to the extent that no conflict arises between the incorporated content and the current disclosures.

Variations of the above devices may have application in robotic-assisted treatments and procedures as well as in traditional treatments and procedures performed by medical professionals. By way of example only, the various teachings herein may be readily incorporated into robotic surgical systems such as the DAVINCI™ system by Intuitive Surgical, Inc. (Sunnyvale, California).

The device variations described above may be designed to be disposed of after a single use, or they may be designed to be used multiple times. The variations may, in either or both cases, be reconditioned for reuse after at least one use. Reconditioning may include any combination of the steps of disassembly of the device, followed by cleaning or replacement of particular parts, and subsequent reassembly. In particular, some device variations may be disassembled, and any number of the particular portions or parts of the device may be selectively replaced or removed in any combination. After cleaning and/or replacement of particular parts, some device variations may be reassembled for subsequent use either at a reconditioning facility or by a user immediately prior to a procedure. Those skilled in the art will appreciate that reconditioning of a device may utilize a variety of techniques for disassembly, cleaning/replacement, and reassembly. The use of such techniques, and the resulting reconditioned device, are all within the scope of the present application.

By way of example only, the variations described herein may be sterilized before and/or after treatment. In one sterilization technique, the device is placed in a closed and sealed container, such as a plastic or TYVEK bag. The container and device may then be placed in a field of radiation that can penetrate the container, such as gamma radiation, x-rays, or a high-energy electron beam. The radiation may kill bacteria on the device and in the container. The sterilized device may then be stored in the sterile container for later use. The device may also be sterilized using any other technique known in the art, including, but not limited to, beta or gamma radiation, ethylene oxide, or steam.

Although various embodiments of the present invention have been shown and described above, further adaptations of the methods and systems described herein may be realized by those skilled in the art through appropriate modifications without departing from the scope of the present invention. Although some of such possible modifications have been described, other modifications will be apparent to those skilled in the art. For example, the above examples, embodiments, shapes, materials, dimensions, ratios, steps, etc. are illustrative and not essential. Therefore, the scope of the present invention should be considered in terms of the following claims and should not be understood to be limited to the details of structure and operation shown and described in this specification and drawings.

[Embodiment]
(1) A staple cartridge configured for use with a surgical stapler, comprising:
(a) a cartridge body;
(b) a deck defined by the cartridge body, the deck configured to compress tissue against an anvil of the surgical stapler; and
(c) a plurality of staple openings formed in the deck;
(d) a plurality of staples disposed within the staple opening, each of the staples including a pair of legs; and
(e) a plurality of staple drivers disposed within the staple opening, the staple drivers being operable to drive the staples through tissue and against the anvil to form the legs, each of the staple drivers comprising:
(i) a driver body;
(ii) a first pocket disposed on a first side of the driver body;
(iii) a second pocket disposed on a second side of the driver body;
the first pocket and the second pocket are configured to receive the legs of each of the staples when the legs are formed against the anvil; and a plurality of staple drivers.
(2) The staple cartridge according to claim 1, wherein the first pocket and the second pocket are open to an upper end of the driver body.
(3) The staple cartridge of claim 1, wherein each of the staple drivers further includes a first boss disposed on the first side of the driver body and a second boss disposed on the second side of the driver body, the first boss defining a side wall of the first pocket and the second boss defining a side wall of the second pocket.
(4) The staple cartridge of claim 1, wherein the first pocket is defined by a first chamfered surface on the first side of the driver body and the second pocket is defined by a second chamfered surface on the second side of the body.
(5) The staple cartridge of claim 4, wherein an upper portion of the first chamfered surface and the second chamfered surface are angled toward one another.

(6) The staple cartridge of claim 1, further comprising a plurality of standoff members disposed on the deck, the standoff members configured to protrude in a direction away from the deck and engage tissue.
(7) The staple cartridge of claim 6, wherein at least a portion of the standoff members each include an end portion that circumscribes a portion of an adjacent staple opening.
(8) The staple cartridge of claim 7, wherein the end portions include rounded end surfaces configured to face respective ones of the staple drivers when the staple drivers are actuated.
The staple cartridge of claim 6, wherein the standoff member comprises a ramp mechanism disposed at a distal end of the deck.
10. The staple cartridge of claim 9, further comprising a post disposed on a distal end of the deck, the ramp mechanism being disposed distally of and in longitudinal alignment with the post along a longitudinal axis of the staple cartridge.

(11) A method for providing a cutting tool, comprising: (a) forming an elongated slot in the deck, the elongated slot being configured to slidably receive a cutting member therethrough, the staple openings being aligned with the elongated slot;
(b) a pair of elongated ribs disposed on the deck, the pair of elongated ribs extending longitudinally along opposing sides of the elongated slot.
(12) The staple cartridge of claim 1, wherein the cartridge body extends linearly along a longitudinal axis.
(13) A surgical stapler, comprising:
(a) a first stapler half having a first distal portion supporting an anvil;
(b) a second stapler half having a second distal portion;
(c) the staple cartridge of claim 1;
the second distal portion is configured to receive the staple cartridge;
A surgical stapler, wherein the first stapler half and the second stapler half are configured to be releasably coupled to one another to clamp tissue between the anvil and the staple cartridge.
14. The surgical stapler of claim 13, wherein each of the staples includes a crown from which the pair of legs extend, and wherein the anvil is configured to form the legs of the staples such that, as the legs are formed, leg tips of each staple are laterally offset from one another and on either side of the crown.
(15) The second stapler half is
(i) a firing assembly selectively actuable in a distal direction to actuate the staple driver to drive the staple from the staple openings, through tissue and against the anvil, a lower surface of the firing assembly including a recess;
(ii) an elastic member;
when the staple cartridge is not present in the second distal portion, the resilient member is configured to bias the firing assembly to a locked state, thereby preventing distal actuation of the firing assembly;
14. The surgical stapler of claim 13, wherein when the staple cartridge is initially seated within the second elongated member, the firing assembly is configured to assume a fired state in which the firing assembly is translatable distally over the resilient member in a deflected state such that a portion of the resilient member is received within the recess of the firing assembly.

16. The surgical stapler of claim 15, wherein the second stapler half further includes a guide member having a channel, the resilient member extending longitudinally through the channel, the resilient member configured to resiliently bias within the channel when the firing assembly is advanced distally.
(17) A staple cartridge configured for use with a surgical stapler, comprising:
(a) a cartridge body;
(b) a deck defined by the cartridge body, the deck configured to compress tissue against an anvil of the surgical stapler; and
(c) a plurality of staple openings formed in the deck;
(d) a plurality of staples disposed within the staple openings, each of the staples including a first leg and a second leg; and
(e) a plurality of staple drivers disposed within the staple opening, the staple drivers being operable to drive the staples through tissue and against the anvil to form the legs, each of the staple drivers comprising:
(i) a first side having a first chamfer;
(ii) a second side having a second chamfered surface;
a plurality of staple drivers, the first chamfered surface configured to receive the first leg of a respective staple in a facing arrangement and the second chamfered surface configured to receive the second leg of each staple in a facing arrangement when the first leg and the second leg are formed against the anvil.
18. The staple cartridge of claim 17, wherein an upper end of each of the staple drivers is configured to support a respective staple, and wherein the first chamfered surface and the second chamfered surface extend to the upper end.
(19) A surgical stapler, comprising:
(a) a first elongated member having a distal portion supporting an anvil;
(b) a second elongated member having a distal portion configured to receive a staple cartridge, the first elongated member and the second elongated member being configured to be releasably coupled to one another to clamp tissue between the anvil and the staple cartridge; and
(c) a guide member secured to the second elongated member; and
(d) an elastic member fixed to the guide member;
(e) a firing assembly slidably coupled to the second elongated member, a lower surface of the firing assembly including a recess, the guide member configured to guide translation of a portion of the firing assembly relative to the second elongated member;
when a staple cartridge is not present on the second elongated member, the resilient member is configured to bias the firing assembly to a locked out condition, thereby preventing distal actuation of the firing assembly;
A surgical stapler configured to assume a fired state when an unused staple cartridge is seated within the second elongated member, wherein the firing assembly is translatable distally over the resilient member in a deflected state such that a proximal end of the resilient member is received within the recess of the firing assembly.
20. The surgical stapler of claim 19, wherein the resilient member extends longitudinally through the guide member, the resilient member configured to resiliently bias within the guide member when the firing assembly is advanced distally.

Claims (18)

1. A staple cartridge configured for use with a surgical stapler, comprising:
(a) a cartridge body;
(b) a deck defined by the cartridge body, the deck configured to compress tissue against an anvil of the surgical stapler; and
(c) a plurality of staple openings formed in the deck;
(d) a plurality of staples disposed within the staple openings, each of the staples including a crown and a pair of legs extending from the crown ; and
(e) a plurality of staple drivers disposed within the staple opening, the staple drivers being operable to drive the staples through tissue and against the anvil to form the legs, each of the staple drivers comprising:
(i) a driver body having an upper end supporting the crown of each of the staples ;
(ii) a first pocket disposed on a first side of the driver body;
(iii) a second pocket disposed on a second side of the driver body;
the first pocket and the second pocket are configured to receive the legs of the respective staples such that the legs do not contact the driver body when the legs are formed against the anvil ;
a staple cartridge, wherein the first pocket is defined by a first chamfered surface on the first side of the driver body and the second pocket is defined by a second chamfered surface on the second side of the driver body . The staple cartridge of claim 1 , wherein said first pocket and said second pocket are open to said top end of said driver body. The staple cartridge of claim 1, wherein each of the staple drivers further includes a first boss disposed on the first side of the driver body and a second boss disposed on the second side of the driver body, the first boss defining a sidewall of the first pocket and the second boss defining a sidewall of the second pocket. The staple cartridge of claim 1 , wherein each of said staple drivers is interconnected with an adjacent said staple driver . The staple cartridge of claim 4, wherein the top portions of the first chamfered surface and the second chamfered surface are angled toward one another. The staple cartridge of claim 1, further comprising a plurality of standoff members disposed on the deck, the standoff members configured to protrude away from the deck and engage tissue. The staple cartridge of claim 6, wherein at least some of the standoff members each include an end portion that circumscribes a portion of an adjacent staple opening. 8. The staple cartridge of claim 7, wherein the end portions include rounded end faces configured to face respective ones of the staple drivers when the staple drivers are actuated. The staple cartridge of claim 6, wherein the standoff member includes a ramp mechanism disposed at a distal end of the deck. The staple cartridge of claim 9, further comprising a post disposed at a distal end of the deck, the ramp mechanism being disposed distal to and in longitudinal alignment with the post along a longitudinal axis of the staple cartridge. (a) an elongated slot formed in the deck configured to slidably receive a cutting member therethrough, the staple opening being aligned with the elongated slot;
2. The staple cartridge of claim 1, further comprising: (b) a pair of elongated ribs disposed on said deck, said pair of elongated ribs extending longitudinally along opposing sides of said elongated slot. The staple cartridge of claim 1 , wherein the cartridge body extends linearly along a longitudinal axis of the surgical stapler . 1. A surgical stapler comprising:
(a) a first stapler half having a first distal portion supporting an anvil;
(b) a second stapler half having a second distal portion;
(c) the staple cartridge of claim 1,
the second distal portion is configured to receive the staple cartridge;
A surgical stapler, wherein the first stapler half and the second stapler half are configured to be releasably coupled to one another to clamp tissue between the anvil and the staple cartridge. 14. The surgical stapler of claim 13 , wherein the anvil is configured to form the legs of the staples such that as the legs are formed, leg tips of each staple are laterally offset from one another and from the crown on either side of the crown. a first elongated member having a distal portion supporting an anvil, and a second elongated member having a distal portion configured to receive a staple cartridge, wherein the first and second elongated members are configured to be releasably coupled to one another to clamp tissue between the anvil and the staple cartridge,
The second stapler half includes:
(i) a firing assembly selectively actuable in a distal direction to actuate the staple driver to drive the staple from the staple opening, through tissue and against the anvil, a lower surface of the firing assembly including a recess;
(ii) an elastic member;
when the staple cartridge is not present in the second distal portion, the resilient member is configured to bias the firing assembly to a locked state, thereby preventing distal actuation of the firing assembly;
14. The surgical stapler of claim 13, wherein when the staple cartridge is initially seated within the second elongated member, the firing assembly is configured to assume a fired state in which the firing assembly is translatable distally over the resilient member in a deflected state such that a portion of the resilient member is received within the recess of the firing assembly. 16. The surgical stapler of claim 15, wherein the second stapler half further includes a guide member having a channel, the resilient member extending longitudinally through the channel, and the resilient member configured to resiliently deflect within the channel when the firing assembly is advanced distally. 1. A staple cartridge configured for use with a surgical stapler, comprising:
(a) a cartridge body;
(b) a deck defined by the cartridge body, the deck configured to compress tissue against an anvil of the surgical stapler; and
(c) a plurality of staple openings formed in the deck;
(d) a plurality of staples disposed within the staple openings, each of the staples including a crown and first and second legs extending from the crown ; and
(e) a plurality of staple drivers disposed within the staple opening, the staple drivers being operable to drive the staples through tissue and against the anvil to form the first and second legs, each of the staple drivers comprising:
(i) a driver body having an upper end supporting the crown of each of the staples;
( ii ) a first chamfered surface disposed on a first side of the driver body ;
( iii ) a second chamfered surface disposed on a second side of the driver body ;
a plurality of staple drivers, wherein the first chamfered surface is configured to receive the first leg of a respective staple in a non-contacting, facing arrangement and the second chamfered surface is configured to receive the second leg of each staple in a non-contacting, facing arrangement when the first leg and the second leg are formed against the anvil. The staple cartridge of claim 17, wherein said first chamfered surface and said second chamfered surface extend to said upper end.

Images